Disposable service package and method for preparing same



Sept. 22, 1964 D. A. SANN] I 3,149,981

DISPOSABLE ssavxcs PACKAGE AND METHOD FOR PREPARING SAME Filed Nov. 2. .1961

4 Sheets-Sheet 1 J LT 44 /00 4 96/4 8.? a Q a mvswrom oommlc A. SANNI ATTORNEYS D. A. SANNI Sept. 22, 1964' DISPOSABLE SERVICE PACKAGE AND METHOD FOR PREPARING SAME Filed Nov. 2, 1961 4 Sheets-$heet 2 BY W ATTORNEYS D. A. SANNI Sept. 22, 1964 DISPOSABLE SERVICE PACKAGE AND METHOD FOR PREPARING SAME 4 Sheets-Sheet 3 Filed NOV. 2, 1961 INVENTOR.

D O M l N I C A. SANNI ATTORNEYS Sept. 22, 1964 D. A. S-ANNl 3,149,981

DISPOSABLE SERVICE PACKAGE AND METHOD FOR PREPARING SAME Filed Nov. 2, 1961 4 Sheets-Sheet 4 DOMINIC A. SANNI ATTORNEYS BY W M MMM United States Patent 3 149,981 DISPOSABLE SERVIC PACKAGE AND METH'DD FOR PREPARTWG SAME Dominic A. Sanni, 31 Ledgetree Road, Mediield, Mass. Filed Nov. 2, 1961, Ser. No. 149,711 7 (Ilairns. (Q1. 99-171) This invention relates to single service commodity packages and more particularly to a package commonly known as a coffee take-out service kit.

Disposable coffee take-out service kits are provided to customers who purchase coffee for consumption elsewhere. A typical cofi'ee service kit consists of a package which contains a predetermined quantity of sugar, a wooden or plastic stirrer and a napkin. However, these packages are relatively expensive. The chief factor in cost is the manual labor involved. The sugar is supplied in a separate envelope which is hand fed into the final package together with the stirrer and napkin. Accordingly, while these packages are popular, they have not been as widely used as they might be if their cost were reduced.

Accordingly, the primary object of the present invention is to provide a novel coffee take-out service kit which is less expensive to manufacture than other kits of the same type heretofore available. With the present invention, a reduction in cost is achieved by elimination of all manual effort. Instead, the packages are manufactured wholly by automatic machinery according to a novel and inventive method.

A further object of the present invention is to provide a method of making a coffee take-out service kit which comprises novel means for inserting a napkin in the kit.

Other objects and many of the attendant advantages of the present invention will be readily appreciated as the invention becomes better understood by reference to the following detaileddescription when considered in connection with the accompanying drawings, wherein:

FIG. 1 is a fragmentary front elevation of a machine embodying the present invention;

FIG. 2 is a plan view of a portion of the apparatus shown in FIG. 1;

FIG. 3 is a side elevation, partly in section, of some of the apparatus of FIG. 1;

FIG. 4 is an enlarged side elevation of the stick feeding unit, with a portion of the stick magazine broken away for clarity;

FIG. 5 is a sectional view taken along line 55 of FIG.

FIG. 6 is a perspective view illustrating how a web of napkin material is fan-folded for inclusion in a coffee take out service kit according to the present invention; and

FIG. 7 is a perspective view schematically illustrating how packages are formed according to the present invention.

The package and the method of manufacture embodying the present invention are described hereinafter in hand with the description of the construction and mode of operation of the apparatus shown in the drawings.

Referring now to FIGS. 1 and 2, the illustrated apparatus comprises two heated sealing rolls 2 and 4 between which two identical webs of heat sealable packaging material 6 and 8 are fed from suitable supply rolls (not shown). The webs 6 and 8 pass over appropriate guide rolls It and 12 before passing down between the two sealing rolls 2 and 4. The two sealing rolls are identical, having at one end continuous peripheral sealing lands 14 and 14A and at the other end peripheral sealing lands 16 and 16A which are divided into two equal sections by two diametrically opposed slots or flats l8 and 18A. Intermediate their two end lands, the two sealing rolls have a third continuous peripheral seal ng land. These are identi- 3,149,981 Patented Sept. 22, 1964 fied at 29 and NA respectively. It is to be noted that the axial distance between lands 14 and 20 is greater than the axial distance between lands 16 and 20.

I11 addition to the circumferential sealing lands just described, each roll also has two axially extending diametrically opposed sealing lands. The axial lands for sealing roll 2 are identified at 22, and the corresponding lands for sealing roll 4 are identified at 22A. It is to be noted that the axial lands 22 and 22A are in line with the slots 18 and 18A respectively. The two rolls are positioned so that their circumferential lands are aligned with each other and also so that their axial lands and their slots 18 and 18A are in the same angular positions.

The sealing rolls 2 and 4 are mounted on identical s .afts 26 and 26A which are driven in opposition to each other as shown in FIGS. 1 and 2. These shafts are driven by drive means of conventional character which are omitted from the drawings for convenience of illustration. While the rolls 10 and 12 may be idler rolls, it is also understood that they may be driven in synchronism with the sealing rolls 2 and 4. This is optional.

Supported above the sealing rolls on a suitable frame member 39 is a feeder mechanism identified generally at 32 (FIG. 3) for discharging measured quantities of sugar into a funnel tube 34- whose bottom end is positioned between rolls 2 and 4?. Tube 34 is supported by an arm 36 (not shown) which is attached to frame member 30 or to some other part of the machine frame (not shown). The feeder mechanism for discharging sugar into the funnel tube 34 comprises a stationary plate 40 of circular configuration which has a discharge opening 42 disposed so as to discharge sugar into an inclined discharge tube 44 which directs the sugar into the funnel tube 34. The stationary plate 49 has a circular opening in which is journaled a rotatable shaft 48. This shaft is driven (by means not shown) in synchronism with sealing rolls 2 and 4. Keyed to the shaft 48 is a circular plate 50. This plate is held in spaced alignment with the stationary plate 4t) by means of an integral spacer 52 which rotates within a sleeve 56 mounted on the supporting plate 40. Plate 59 is restrained against movement in an upward direction by a circular plate 53. The latter is provided with an opening 69 which is located directly below a funnel-shaped hopper 62 which is designed to hold a large supply of sugar S. The plate 563 is provided with four equally spaced holes in which are secured open-ended sleeves 66. These sieeves lightly engage the upper surfaces of the stationary plate 46. The distance of the opening 60 measured from the shaft 48 is precisely the same as the distance of the opening 42 measured from the same shaft. Accordingly, when the plate 5! is rotated by the shaft 43, each sleeve 66 in turn will be rotated into and out of registration with openings 60 and 42. Sugar which falls into a sleeve 66 located below the hopper 62 will be carried around with the sleeve to the opening 42 Where it will fall by gravity into the discharge tube 44 which will direct it into the funnel tube 34. The amount of sugar which is contained in each sleeve 66 is precisely the amount desired to be deposited into the packages to be formed. The amount of sugar which is contained in the sleeves 66 is determined by the length of the sleeves and also by their internal diameter. Necessarily, the sleeves can accumulate sugar only to their top ends. Any tendency to carry more is defeated by plate which produces wiping action.

It is to be observed that the funnel tube 34% is positioned between the two continuous circumferential seals 14 and 2% Also disposed between the two sealing rolls in the same region is a feed tube 70. The latter is supported by an arm (not shown) attached to frame member 30. Tube 7%) is of rectangular cross-section at its discharge end, its cross-section becomes progressively larger in one dimension towards its upper end which bends laterally c3 Over thesealing roll 2 ("as illustrated in FIGS. 1 and 2). The top end of the tube 70 is located in line with the discharge end of a stick feeder 74 mounted on a platform (not shown) supported by frame members or by some other part of the machine frame (not shown). The stick feeder 74 is a relatively simple construction, comprising a magazine 76 in which a plurality of stirrer sticks T can be stacked one above the other, and a reciprocating slide 78 which is operated by a crank arm 80 mounted on a crank wheel 82 carried by a shaft 84 which is operated in synchronism with shaft 48 and sealing rolls 2 and 4 by suitable mechanism (not shown). Slide 78 operates to eject sticks T one at a time, the ejected sticks being discharged into the upper end of feed tube 70 and directed by the latter into the space between seals 14, 14A and 20, A of the two sealing rolls 2 and 4. The sticks are discharged into the aforesaid space at the same rate as each charge of sugar and when the lands 22 and 22A are approximately in the positions shown in FIG. 1. It is to be observed that the crank arm 80 is attached to crank wheel 82 by means of a block 86 positioned in an undercut radial groove 88. A thumb screw 9% on the block permits it to be set at any desired position along the crank wheel radius so as to vary the length of the stroke of slide 78. It is to be noted also that the crank wheel is attached to shaft 84 by a set screw 92 which permits the crank wheel to be rotated relative to the shaft in order to advance or retard the feeding of sticks with respect to formation of transverse seals by sealing lands 22 and 22A.

Also located above the two sealing rolls 2 and 4 are two drive rolls 94 and 94A having frictional gripping surfaces 96 and 96A. These rolls are mounted on identical shafts 98 and 98A which are driven by suitable drive means (not shown) in synchronism with the sealing rolls 2 and 4. Mounted above drive rolls 94 and 94A on a shaft 99 is a guide roll 100. Located at the same vertical level as guide roll 100 are two additional drive rolls 102 and 102A (FIG. 6), which are mounted on identical shafts 104 and 104A that are driven in synchronism with shafts 98, 98A, and 99. Rolls 94, MA, 109, 102, and 102A serve to feed fan-folded napkin material down between the two sealing rolls 2 and 4 in the region between the segmented circumferential sealing lands 16 and the continuous circumferential sealing lands 20.

Napkin material N is fed from a supply roll (not shown) which preferably (but not necessarily) is positively driven. As the napkin material N is fed from the feed roll, it passes between two sets of folding shoes 112 and 112A which cooperate to promote fan folding of the napkin material in the manner shown in FIG. 6. The folding operation is completed between rolls 102 and 102A. On passing out from between rolls 102 and 102A, the napkin web N is in the form of a plurality of parallel folds. The folded napkin material has a width slightly less than the distance between the sealing surfaces 16 and 20.

Also forming part of the apparatus are two drive rolls 114 and 114A which are provided at both ends with raised peripheral lands 116 and 116A, respectively, which grip the two webs of packaging material at their edges. Also forming part of drive roll 114 is an axially extending knife blade 118 which mates with an axial knife notch 118A formed in drive roll 114A.

Having described the essential elements of the apparatus, the mode of operation and the product which is formed will now be explained with reference to FIG. 7.

Assuming that webs 6 and 8 are disposed between the two sealing rolls 2 and 4 and also between the two drive rolls 114 and 114A, that the hopper 62 is full of sugar S, that the stick feeder is provided with an ample supply of sticks T, and that napkin material N has been led through the various rolls down between the two sealing rolls 2 and 4, operation of the apparatus is as follows: The two webs 6 and 8 will be sealed together at their opposite edges by the seals 14, 14A and 16, 16A so as to form at one edge a continuous longitudinal seal 120 and at the other edge an intermittent longitudinal seal 122. Seals 122. are intermittent because the flats 18, 18A and 22, 22A do not produce any seal. Simultaneously, another continuous longitudinal seal 124 is formed by the sealing surfaces 2% and NA. Formation of the seals 12d and 124 acts to produce a flattened tubular section which can be converted into a plurality of pouches by a succession of transverse seals identified generally at 126 which are made by axial lands 22 and 22A. The seals made by lands 22 and 22A are of sufficient width as to be severable by blade 118 into two discrete transverse seals 126A and 126B, the latter of which is the end or tail transverse seal of one package and the former of which is the lead transverse seal of the next successive package. As each lead seal 126A is formed, the trailing portion of the web acts as a pouch 128 into which sugar and a stirrer stick are deposited by their respective feeder mechanisms. The stick is discharged before the sugar or simultaneously with the first part of the sugar charge so as to assure that the stick will fall down into the pouch as far as possible, i.e., to the lead seal 126A. The stick and sugar charge are deposited before formation of the tail seal 126B which produces a fully sealed pouch identified generally at 134.

At the same time that the pouches 134 are being manufactured, the accordion-folded napkin Web N is being captivated between the seals 122 and 124. The spacing between seals 122 and 124 and the widths of the folded web N are such that the napkin material is held snugly between the two webs 6 and 8. As the webs 6 and 8 pass between rolls 114 and 114A, they are severed along the center line of each transverse seal 126, forming the aforementioned separate lead and tail seals 126A and 126B, respectively. Severing of the webs by knife 118 not only separates the series of scaled pouches 134 but also cuts the web of napkin material. As a consequence, each separated unit is a complete package having front and rear walls formed from the webs 6 and 8 and having (1) a pouch containing sugar and a stirrer and (2) a separate multi-folded napkin N.

It is to be noted that the seal 122 is intermittent. This is for a practical purpose-to allow the webs 6 and 8 to be separated easily at the corner of the package so as to permit access to the napkin. In this way, the napkin can be pulled out easily without need for tearing open the sugar pouch and without the risk of damage to the napkin.

Of course, it is not necessary to form the kit with a wooden stirrer in the sugar compartment. It is contemplated that the stirrer may be omitted. It is further contemplated that the material which is contained with the stirrer in a separate pouch may be something other than sugar, as for example, saccharin, or even an instant coffee or tea. It is further contemplated that the stirrer could be captivated in a separate elongated compartment.

Cofiee service kits made as just described have one great advantage over colfee service kits heretofore availablethey are far less expensive to manufacture. The reduced cost of manufacturing is due to the fact that the entire package is made without manual labor. The stick, the sugar, and the napkin are all introduced automatically by machine. A further advantage of the present invention is the fact that the size of the napkin can be varied by increasing the number of folds, or preferably by increasing the width of the package so as to accommodate a fan-folded napkin web of greater width. The size of the napkin can also be increased by increasing the length of the package. 0f course, the amount of sugar which is contained in each pouch can also be varied. It is to be appreciated also that overall printing of the package is possible by reprinting the webs 6 and 8 prior to introducing them into the apparatus. A further ad vantage of the illustrated machine is that it can be used to manufacture regular sugar packets, that is, packets which contain simply sugar. When it is desired to do this, the webs 6 and 8 are made just wide enough to ride over the lands 14 and 20 but not the land 16. Of course, the stick feeder and also the napkin section will be deactivated when straight sugar packets are being manufactured.

Still another advantage of the present machine is that it is easy to construct and maintain, using many parts and embodying certain operating principles which are conventional in the packaging field. Thus, for example, although the specific form of the heat sealing rolls 2 and 4 is new, the general concept of heat sealing rolls and how to heat them and mount them is old.

Obviously, many modifications and variations of the present invention are possible in the light of the above teachings. Thus, for example, the packaging material may be opaque, transparent or translucent and may be provided with advertising on its exterior face. Similarly the single set of sealing rolls 2 and 4 can be replaced by two sets of rolls disposed one above the other, with the upper ones designed to make the longitudinal seals and the lower ones the transverse seals. Moreover, the knife could be made separate from drive rolls 114 and 114A as in conventional packaging machines. It is to be understood, therefore, that the invention is not limited in its application to the details of construction and arrangement of parts specifically described or illustrated, and that within the scope of the appended claims, it may be practiced otherwise than as specifically described or illustrated.

What is claimed is:

1. A coifee service kit comprising a rectangular package having a front wall and a back wall, said front and back walls sealed together to form two compartments, one of said compartments containing an edible commodity, the other of said compartments open at two opposite ends and containing an accordion-pleated napkin.

2. A method of forming a service kit for diners comprising continuously bringing together two webs of flexible packaging material, forming longitudinal seals at the edges of said webs and along an intermediate line, repeatedly sealing said webs together along spaced transversely extending areas to make a series of sealed pouches in the space between one of said edge seals and said intermediate seal, inserting a charge of edible commodity into each pouch before it is completed, continually feeding an accordion-folded web of napkin material in the space between the other edge seal and said intermediate seal as said other and intermediate seals are being formed, and severing all of said webs along the center lines of successive transverse seals whereby to provide individual packages each containing a sealed charge of commodity and an accordion-folded napkin.

3. The method of claim 2 wherein said other edge seal is formed intermittently with interruptions at each transverse seal.

4. A compartmented container comprising a pair of rectangular facing sheets each having two opposite side edges and two opposite end edges, said sheets secured together by longitudinal seals extending along said two side edges and also along a line intermediate and parallel to said side edges, said sheets also secured together at said opposite end edges by transverse seals extending from one said side edges to the line intermediate and parallel to said opposite side edges, whereby to form one compartment closed at its ends and a second compartment open at its ends, an edible commodity in said one compartment, and a napkin disposed in said second compartment, said napkin folded accordion-wise with its fold lines extending parallel to said opposite side edges.

5. A compartmented container as defined by claim 4 wherein said napkin is coextensive with said side edge.

6. A compartmented container as defiined by claim 4 wherein the longitudinal side edge seal of said second compartment terminates short of one of said opposite end edges, whereby to facilitate separation of said sheets for removal of said napkin.

7. A service kit for diners in the form of a rectangular package comprising a front wall and a back wall sealed together so as to form two compartments, one of said compartments containing an edible commodity, the other of said compartmens being open at two opposite ends, and an accordion-folded napkin disposed in said other compartment, the fold lines of said napkin extending at right angles to said open ends.

References Cited in the file of this patent UNITED STATES PATENTS 1,693,841 Gaylord Dec. 4, 1928 2,034,067 Stone Mar. 17, 1936 2,245,738 Taylor June 17, 1941 2,782,912 Humphrey Feb. 26, 1957 2,791,324 Knopp et al. May 7, 1957 

7. A SERVICE KIT FOR DINERS IN THE FORM OF A RECTANGULAR PACKAGE COMPRISING A FRONT WALL AND A BACK WALL SEALED TOGETHER SO AS TO FORM TWO COMPARTMENTS, ONE OF SAID COMPARTMENTS CONTAINING AN EDIBLE COMMODITY, THE OTHER OF SAID COMPARTMENTS BEING OPEN AT TWO OPPOSITE ENDS, AND AN ACCORDION-FOLDED NAPKIN DISPOSED IN SAID OTHER COMPARTMENT, THE FOLD LINES OF SAID NAPKIN EXTENDING AT RIGHT ANGLES TO SAID OPEN ENDS. 